Systems and methods comprising open cell pack modules

ABSTRACT

In one aspect, an embodiment of this invention comprises an energy-storage module for storing energy for electrical consumption. The module comprises a plurality of energy-storage cells and a set of parallel walls configured to mount the plurality of energy-storage cells between the parallel walls and having a plurality of through-holes. The module also comprises a bus bar arrangement configured to electrically couple each of the plurality of energy-storage cells to a first terminal and a second terminal and a wire routing device configured to mate with a plurality of the through-holes and configured to receive one or more wires that electrically connect components of the energy storage module.

BACKGROUND Field

The present disclosure relates generally to energy storage devices andsystems, such as capacitor and/or battery modules and systems, includingultra-capacitors and super-capacitors, and in particular, capacitorand/or battery modules deployed in low, medium, or high voltage seriesconfigurations, each module containing some number of capacitor orbattery cells and coupled to some number of other modules.

Description of the Related Art

Various techniques exist for constructing capacitor and/or batterymodules (hereinafter “modules”) used in direct current (DC) systems.Combining the individual capacitor and/or battery cells (cells) into themodules may provide for varied voltages based on a quantity of combinedcells. The modules may store power for on demand use by various systems.However, forming the modules is a complicated process, especially as thequantity of cells in the modules increases. The modules may includevarious components, from spacers that enable proper placement of thecells within the module to conductors that electrically couple theindividual cells together to obtain the benefits of the combinedvoltages. Additionally, the modules may often require cooling componentsto maintain temperatures of the cells contained therein within anoperating range of temperatures.

Accordingly, the prior approaches of constructing the modules tophysically and electrically couple the cells require a large number ofparts, increasing costs, possible points of failure, module complexity,and maintenance difficulties.

SUMMARY

Embodiments disclosed herein address the above-mentioned problems withprior art. The systems, methods and devices of this disclosure each haveseveral innovative aspects, no single one of which is solely responsiblefor the desirable attributes disclosed herein.

Various embodiments of methods and devices within the scope of theappended claims each have several aspects, no single one of which issolely responsible for the desirable attributes described herein.Without limiting the scope of the appended claims, some prominentfeatures are described herein.

In one aspect, an embodiment of this invention comprises anenergy-storage module for storing energy for electrical consumption. Themodule comprises a plurality of energy-storage cells and a set ofparallel walls configured to mount the plurality of energy-storage cellsbetween the parallel walls and having a plurality of through-holes. Themodule also comprises a bus bar arrangement configured to electricallycouple each of the plurality of energy-storage cells to a first terminaland a second terminal and a wire routing device configured to mate witha plurality of the through-holes and configured to receive one or morewires that electrically connect components of the energy storage module.

In one other aspect, an embodiment of this invention comprises a methodfor manufacturing an energy-storage module for storing energy forelectrical consumption. The method comprises mounting a set of parallelwalls on opposite ends of a plurality of energy-storage cells such thatthe plurality of energy-storage cells are positioned between theparallel walls, each of the parallel walls having a plurality ofthrough-holes. The method also comprises electrically coupling each ofthe plurality of energy-storage cells to a first terminal and a secondterminal via a bus bar arrangement. The method further comprises matinga wire routing device with a plurality of the through-holes, the wirerouting device configured to receive one or more wires that electricallyconnect components of the energy storage module.

In one other aspect, an embodiment of this invention comprises anenergy-storage module for storing energy for electrical consumption. Theapparatus comprises means for storing energy between means for mountingthe means for storing energy. The apparatus further comprises means forelectrically coupling the means for storing energy to a first means forconnecting and a second means for connecting. The apparatus alsocomprises means for routing wire within the energy-storage module.

BRIEF DESCRIPTION OF THE DRAWINGS

Details of one or more embodiments of the subject matter described inthis disclosure are set forth in the accompanying drawings and thedescription below. Although the examples provided in this disclosure aresometimes described in terms of capacitors or capacitor cells, theconcepts provided herein may apply to other types of energy storagesystems. Other features, aspects, and advantages will become apparentfrom the description, the drawings and the claims. Note that therelative dimensions of the following figures may not be drawn to scale.

FIG. 1 illustrates an isometric view of an open cell module comprising aplurality of components that together form the module, in accordancewith an embodiment.

FIGS. 2A-2C illustrate embodiments in a top isometric (FIG. 2A), abottom isometric (FIG. 2B), and a side view (FIG. 2C), respectively, ofa terminal bracket used to couple the open cell module of FIG. 1 to adevice external to the module.

FIGS. 3A-3C illustrate embodiments in a top isometric (FIG. 3A), abottom isometric (FIG. 3B), and a side view (FIG. 3C), respectively, ofa bus bar bracket used to couple adjacent cells of the open cell moduleof FIG. 1 to each other (for example, in series or parallel).

FIG. 4 illustrates a side plate or wall of the open cell module of FIG.1, in accordance with an embodiment.

FIGS. 5A-5C illustrate an isometric view (FIG. 5A), a top view (FIG.5B), and a front view (FIG. 5C), respectively, of a wire way or wirerouting device, in accordance with an embodiment.

FIG. 6 illustrates an isometric view of the wire routing device of FIG.5 incorporated into the side plate of FIG. 4 of the open cell module ofFIG. 1.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appendeddrawings is intended as a description of exemplary embodiments and isnot intended to represent the only embodiments in which the inventionmay be practiced. The term “exemplary” used throughout this descriptionmeans “serving as an example, instance, or illustration,” and should notnecessarily be construed as preferred or advantageous over otherexemplary embodiments. The detailed description includes specifieddetails for the purpose of providing a thorough understanding of theexemplary embodiments. In some instances, some devices are shown inblock diagram form.

Energy storage systems can include a plurality of individual capacitorand/or battery cells arranged in series or parallel to form an energystorage module or bank that has a higher voltage output than anindividual cell. The modules in turn can be connected in series withother modules to output even higher combined voltages. The individualbatteries or capacitors of the energy storage module or bank aresometimes referred to as battery or capacitor cells, or more generally,cells. The individual energy storage modules or banks are sometimesreferred to generally as modules.

Depending on the individual cells use in the module, various componentsmay be utilized to form the module. For example, the module may comprisea housing to contain each of the individual cells within a definedvolume for ease of transport, installation, etc. The housing may providestructural support for the module as well as provide protection fromenvironmental concerns (for example, debris, moisture, etc.) as needed.Additionally, the module may comprise one or more conductors or bus barsto couple electrically the individual cells to obtain the desired modulevoltage or circuit structure. In some embodiments, the module maycomprise multiple individual bus bars (for example, wires or conductors)that couple an end of each cell to an end of another cell (for example,in a series chain). In some embodiments, the module may comprisemultiple bus bars, for example one that couples to one end of each celland a second that couples to the other end of each cell (for example, ina parallel connection). In some embodiments, the bus bars may connecteach cell of the module to a terminal of the module. The terminal of themodule may comprise a physical point or connection at which the moduleis electrically connected or coupled to another module, component, orsystem. In some embodiments, the module may comprise a plurality ofterminals (for example, two, three, four, or more terminals).

In some embodiments, the module may include one or more structuralmembers or fillers that hold the cells in place within the modules. Insome embodiments, the structural members or fillers may comprise anepoxy that fills the interior of the module and holds the cells inplace. In some embodiments, the fillers may have a solid or liquid stateafter setting such that the fillers may provide structural support tothe cells. In some embodiments, the fillers may also provide thermalbenefits to the cells and the module. In some embodiments, thestructural members may comprise one or more holders that physicallycontact more than one of the cells of the modules. For example, thestructural members may comprise an array of supports that hold each ofthe cells to the members and/or to other cells. In some embodiments, themodule may comprise one or more interconnects or similar conductors thatcontrol various signals between the cells of the module or betweenmodules. However, placing the interconnects or similar conductors withinthe module between the various cells, the bus bars, and the structuralmembers or fillers may be difficult to do and may result in a physicallycomplex module with minimal free space between the cells within themodule. Additionally, the quantity of components and the reduced fillspace of the module may result in reduced airflow through the moduleand, thus, may cause increased temperatures within the module. Thus, themodule may utilize supplemental cooling components (for example, fans,etc.) to help maintain the module within safe operating temperatures.

Such congestion within the module may be reduced by utilizing an opencell module structure. The open cell module may not comprise an enclosedmodule, instead keeping the cells open to the environment of the opencell module. Such an embodiment may have reduced concerns regardingtemperatures within the module, as the open-air nature may providenatural cooling for the open cell module. Alternatively, oradditionally, instead of each open cell module utilizing its own coolingfeature, one or more cooling features may be shared between multipleopen cell modules. Accordingly, an interior of the open cell module mayhave reduced congestion at least due to the removal of the coolingfeatures. Additionally, the open cell module as described herein mayutilize a more streamlined module layout as compared to the non-opencell modules. For example, the bus bars used to couple the cells of theopen cell module may be positioned on the exterior of the side plates.Accordingly, the interior of the open cell module may have reducedcongestion at least due to the removal of all or a majority of the busbars. Furthermore, the open cell module described herein may utilizewire guides that may be attached to one or both of the side walls butbetween the cells of the open cell module. For example, the wire guidesmay comprise structural supports that can be placed in a manner suchthat the interconnects and other wires within the module or passingthrough the module are held in place by the structural supports. Such anopen cell module as described herein is shown in FIG. 1 and will bedescribed in further detail below.

FIG. 1 illustrates an isometric view of an open cell module 100comprising a plurality of components that together form the open cellmodule 100, in accordance with an embodiment. In some embodiments, theopen cell module 100 may comprise a plurality of side plates 400 a,b oneor more bus bar brackets 300, and one or more terminal brackets 200. Insome embodiments, the open cell module structure and the componentsdescribed above may, in combination, form the open cell module 100.

In an embodiment of the open cell module 100 as described herein, themodule housing may comprise two side plates 400 a,b that are positionedin parallel or substantially in parallel with each other. In someembodiments, the side plates 400 a,b may comprise a plurality ofopenings or cutouts for mounting various components, as will bediscussed further below. In some embodiments, the module housing maycomprise a printed circuit board (PCB) 110 or similar circuit structurecomprising one or more circuits configured to control operation of theopen cell module 100. In some embodiments, a protective cover or shield115 may cover the PCB 110. In some embodiments, the PCB 110 may beintegrated with or into, or positioned between one or both of the sideplates 400 a,b and covered by the cover 115.

The two side plates 400 a,b may each be coupled to one or more braces120 a,b. The braces 120 a,b may provide mounting capabilities to attachthe sides plates 400 a,b (and thus the open cell module 100) to acabinet or other installation point. In some embodiments, each of theside plates 400 a,b may be coupled to two braces (for example, sideplate 400 b may be coupled to braces 120 b and 120 c) or only one brace(for example, side plate 400 a may be coupled to brace 120 a). Betweenthe side plates 400 a,b, a plurality of cells 105 may be installed. Thecells 105 may include the battery or capacitor cells as describedherein. In some embodiments, the cells may be held in place withrelation to the side plates 400 a,b via a plurality of openings orcutouts, as will be described in further detail below. Accordingly, suchuse of the openings or cutouts may eliminate a need for additionalcomponents dedicated to positioning or holding the cells 105 inparticular locations within the open cell module 100. In someembodiments, the cells 105 may be held to the side plates 400 a,b usingvarious brackets. The brackets may be physically coupled to the cells105 across or through the side plates 400 a,b, thus holding the cells105 within a particular cutout or opening in each side plate. Thebrackets may include two styles, bracket 300, which may couple two cells105 together, or bracket 200, which couples one cell 105 to a terminalpin or post 125.

FIGS. 2A-2C illustrate embodiments in a top isometric (FIG. 2A), abottom isometric (FIG. 2B), and a side view (FIG. 2C), respectively, ofa terminal bracket 200 used to couple the open cell module 100 of FIG. 1to a device external to the open cell module 100. In some embodiments,the terminal bracket 200 may be formed from metal (for example,aluminum, etc.) or some conductive material. In some embodiments, theterminal bracket 200 may include dimples or may not include dimples. Forexample, the terminal bracket 200 may be formed or stamped as a singlepiece and then shaped. In some embodiments, the terminal bracket 200 maybe formed from two separate pieces that are coupled together. Theterminal bracket 200 may include two substantially planar portions thatare (or are substantially) orthogonal to each other. The two portionsmay be mechanically and electrically coupled to each other. Portion 205may be the portion of the terminal bracket 200 that is placed againstone of the side plates 400 a,b, as shown in FIG. 1. The portion 205 mayinclude a plurality of holes 215 that pass through the portion 205 in adirection substantially orthogonal to the portion 205. In someembodiments, the holes 215 may be at any angle in relation to theportion 205. In some embodiments, the holes 215 may serve variouspurposes. For example, one or more of the holes 215 may be used toattach cell pack or cell module 100 sense wires to terminal brackets 200using rivets (not shown).

Additionally, in some embodiments, the holes 215 may be used totemporarily hold the terminal brackets 200 in place using the rivetsprior to the terminal brackets 200 being welded to the individual cells105. In some embodiments, the rivets may not be needed to hold theterminal brackets 200 or cells 105 in place once the welding of thecells 105 to the terminal brackets 200 has been completed. Additionally,the portion 205 may include a depressed area 210. The depressed area 210may be depressed into the portion 205 in a direction substantiallyparallel to the portion 220. In some embodiments, the depressed area 210may be at any other angle relative to the portion 220. The depressedarea 210 may have a hole 212 that passes through the portion 205 and theterminal bracket 200. The depressed area 210 may also include threefingers 211 a, 211 b, and 211 c. The portion 220 may have a single hole225 that passes through the portion 220. Additionally, one or more ofthe portions 205 and 220 may include one or more dimples 230.

In some embodiments, the plurality of holes 215 may provide mountingpoints by which the terminal bracket may be fixedly attached to one ormore other components, for example, one of the side plates 400 a,b. Insome embodiments, one or more of the holes 215 may be included in adepressed region of the terminal bracket 200 (not shown). In someembodiments, one or more of the holes 215 may serve as a path throughthe terminal bracket 200 for a wire or other conductor or for anon-conductive support piece. In some embodiments, the one or more holes215 may serve as connection points for a wire or conductor or a mountingpoint for a rivet to couple the terminal bracket 200 to one of the sideplates 400 a,b.

In some embodiments, the depressed area 210 may provide a physical andelectrical connection through one of the plurality of openings orcutouts of the side plates 400 a,b to couple to one of the cells 105included within the open cell module 100. The depressed area 210 may beconfigured to pass into and/or through the opening of one of the sideplates 400 a,b so that the depressed area 210 at least sits within theopening of one of the side plates 400 a,b. In some embodiments, thedepressed area 210 may extend from the portion 205 by a depressed depth214. The depressed depth 214 may be large enough such that it can passthrough the opening of the side plate (for example, the depressed depth214 of the depressed area 210 is larger or deeper than a thickness ofone of the side plates 400 a,b). In some embodiments, the depresseddepth 214 may not be large enough that it passes through the opening butrather only rests within the opening of the side plates (for example,the depressed depth 214 is equal to or less than a thickness of one ofthe side plates 400 a,b). In some embodiments, the depressed area 210may include a plurality of fingers 211 a,b,c. As shown, the depressedarea 210 includes fingers 211 a, 211 b, and 211 c; however, in someembodiments, the depressed area may only include two fingers (forexample, fingers 211 a and 211 b). In some embodiments, the fingers 211a,b,c may provide for mechanisms of holding or positioning the terminalbracket 200 within the opening of one of the side plates 400 a,b whilestill providing sufficient room for transverse movement of the depressedarea 210 within the opening of the side plates 400 a,b. Such allowanceor permissibility of transverse movement may reduce restrictions andconstraints on manufacturing the terminal brackets 200, allowing forgreater tolerances in the dimensions, etc., of the terminal brackets200. In some embodiments, the fingers 211 a,b,c may be stamped into theterminal brackets 200 and may improve stamped part manufacturability. Insome embodiments, the depressed area 210 may be impact formed (forexample, may comprise a cupped feature into the terminal bracket 200(rather than the cut/bent “fingers”). The hole 212 may allow for aportion of the cell 105 (for example, a terminal on one end of the cell105) to pass into or through the depressed area 210. Accordingly, thehole 212 may provide for both physical and electrical coupling betweenthe terminal bracket 200, the plates 400 a,b and the cell 105. In someembodiments, the cell 105 and the terminal bracket 200 may be coupledtogether using welding or some other conductive coupling means to ensureboth the physical and electrical coupling is maintained.

FIGS. 3A-3C illustrate embodiments in a top isometric (FIG. 3A), abottom isometric (FIG. 3B), and a side view (FIG. 3C), respectively, ofa bus bar bracket 300 used to couple adjacent cells 105 of the open cellmodule 100 of FIG. 1 to each other (for example, in series or parallel).In some embodiments, the bus bar bracket 300 may be formed from a typeof metal. The metal may be, for example, aluminum, tin, copper etc. orother conductive material. In some embodiments, the bus bar bracket 300may include dimples or may not include dimples. For example, the bus barbracket 300 may be formed or stamped as a single piece of metal and thenshaped. In some embodiments, the bus bar bracket 300 may be machined. Insome embodiments, the bus bar bracket 300 may be formed from separatepieces that are coupled together. The bus bar bracket 300 may besubstantially planar. The bus bar bracket 300 may be placed against oneof the side plates 400 a,b, as shown in FIG. 1. The bus bar bracket 300may include a notch 315.

In some embodiments, the notch 315 may provide alignment benefits bysimplifying the determination of proper orientation and alignment. Insome embodiments, the notch 315 may be replaced with any otherorientation and alignment identifying feature, such as a dimple, aprotrusion, a different material, and so forth. The bus bar bracket 300may include a plurality of holes 325 that pass through the bus barbracket 300 in a direction substantially orthogonal to the planar busbar bracket 300. In some embodiments, the holes 325 may be at any anglein relation to the bus bar bracket 300. In some embodiments, the holes325 may provide function or purpose as described above in relation tothe holes 215 of the terminal bracket 200. Additionally, the bus barbracket 300 may the include depressed areas 310 and 320. The depressedareas 310 and 320 may be depressed into the bus bar 300 in a directionsubstantially orthogonal to the bus bar bracket 300. In someembodiments, the depressed areas 310 and 320 may be at any angle inrelation to the bus bar bracket 300. The depressed areas 310 and 320 mayeach have a hole 312 and 322, respectively, that passes through the busbar 300. The depressed areas 310 and 320 may also include fingers (forexample, fingers 311 a, 311 b, and 311 c and fingers 321 a and 321 b).

In some embodiments, the plurality of holes 325 may provide mountingpoints by which the bus bar bracket 300 may be fixedly attached to oneor more other components, for example, one of the side plates 400 a,b.In some embodiments, one or more of the holes 325 may be included in adepressed region of the bus bar bracket 300 (for example, the dimple330). In some embodiments, one or more of the holes 325 may serve as apath through the bus bar bracket 300 for a wire or other conductor orfor a non-conductive support piece to pass or rest. In some embodiments,the one or more holes 325 may serve as connection points for a wire orconductor (for example, a sense wire connection point to each cell). Insome embodiments, the sense wire connection point may alternate betweensides of the bus bar bracket 300 (or terminal bracket 200). In someembodiments, the corner hole may only provide coupling of the bracket toa ring lug connection. In some embodiments, the dimples 330 may ensurethat the bus bar bracket 300 contacts a face of the cell 105 just priorto an interior face (for example, face of the bus bar bracket 300 facingthe side plate) of the bus bar bracket 300 contacting one of the sideplates 400 a,b. Such dimples 330 may alleviate variations in side plates400 a,b thickness or bus bar bracket 300 thickness or variations in thesurfaces of the side plates 400 a,b or bus bar bracket 300 that maycause inconsistent laser welds.

In some embodiments, the depressed areas 310 and 320 may providephysical and electrical connections through openings or cutouts of theside plates 400 a,b to couple to two the cells 105 included within theopen cell module 100. In some embodiments, the bus bar 300 and thedepressed areas 310 and 320 may be sized and positioned such that thetwo cells 105 are adjacent to each other. The depressed areas 310 and320 may be configured to pass into and/or through the respectiveopenings of the side plates 400 a,b so that the depressed areas 310 and320 at least sit within the openings of the side plates 400 a,b. In someembodiments, the depressed areas 310 and 320 may each extend from theportion 305 by a depressed depth 314. The depressed depth 314 may belarge enough that it passes through the openings of the side plates 400a,b (for example, the depressed depth 314 of the depressed areas 310 and320 is larger or deeper than a thickness of one of the side plates 400a,b). In some embodiments, the depressed depth 314 may not be largeenough that it passes through the openings but rather only rests withinthe openings of one of the side plates 400 a,b (for example, thedepressed depth 314 is equal to or less than a thickness of one of theside plates 400 a,b).

In some embodiments, the depressed areas 310 and 320 may include aplurality of fingers 311 a,b,c and 321 a,b, respectively. As shown, thedepressed area 310 includes fingers 311 a, 311 b, and 311 c while thedepressed area 320 includes fingers 321 a and 321 b; however, in someembodiments, the depressed area 320 may only include two (or more)fingers (for example, fingers 321 a and 321 b) while the depressed area310 includes three (or more) fingers (for example, fingers 311 a, 311 b,and 311 c). In some embodiments, the fingers 311 a,b,c and 321 a,b mayprovide mechanisms of holding or positioning the bus bar bracket 300within the openings of one of the side plates 400 a,b while stillproviding sufficient room for transverse movement of the depressed areas310 and 320 within the openings of the side plates 400 a,b (and the busbar bracket 300 along one of the side plates 400 a,b). Such allowance orpermissibility of transverse movement may reduce restrictions andconstraints on manufacturing the bus bar brackets 300, allowing forgreater tolerances in the dimensions, etc., of the bus bar brackets 300.In some embodiments, the fingers may provide benefits as described abovein relation to the fingers of the terminal bracket 200. The holes 312and 322 may allow for portions of the cells 105 (for example, a terminalon one end of each of the cells 105) to pass into or through thedepressed areas 310 and 320. Accordingly, the holes 312 and 322 mayprovide for both physical and electrical coupling between the bus barbracket 300, one of the side plates 400 a,b and the cells 105. In someembodiments, the cells 105 and the bus bar bracket 300 may be coupledtogether using welding or some other conductive coupling means to ensureboth the physical and electrical coupling is maintained.

FIG. 4 illustrates a side plate or wall 400 a,b of the open cell module100 of FIG. 1, in accordance with an embodiment. The side plates 400 a,bmay be formed from any non-conductive, rigid material. For example, theside plates 400 a,b may be formed from plastic, resin, or fiberglass.The side plates 400 a,b may include a plurality of holes, openings, orcutouts Each of the holes may pass completely through the side plates400 a,b. The holes may be of different shapes, sizes, and/ororientations. For example, the holes 405 may be the smallest of theholes in the side plates 400 a,b. The holes 405 may comprise a pathwayor “conduit” for wires or conductors that couple to one of the cells 105of the open cell module 100, the open cell module 100 itself, the PCB110 of the open cell module 100, or just pass through the open cellmodule 100. In some embodiments, the holes 405 may provide benefitssecuring (temporarily or permanently) the terminal and bus bar brackets200 and 300, respectively, to one of the side plates 400 a,b usingrivets and/or providing relief for the rivet securing the sense wires tothe bus bars as described above in relation to the fingers of theterminal bracket 200. The holes 410 may be the largest of the holesthrough the side plates 400 a,b. The holes 410 may include the portionof one of the side plates 400 a,b through which the cells 105 couple tothe bus bar or the terminal brackets 300 and 200, respectively.

The holes 410 may be dimensioned such that the fingers 211 a,b,c, 311a,b,c, or 321 a,b and/or the depressed area 210 may fit within the holes410 with some extra clearance to provide transverse movement andflexibility with alignment of the cells 105, the brackets 200 or 300,and one of the side plates 400 a,b. In some embodiments, the holes 410may be substantially circular. In some embodiments, the holes 410 may besubstantially any other shape. The combination of holes 415 may providefor coupling with a wire way or wire routing device, as described inmore detail below. In some embodiments, all or some of the combinationof holes 415 may not be used with the wire routing device. In someembodiments, the holes of the combination of holes 415 may besubstantially elliptical in shape. In some embodiments, the holes of thecombination of holes 415 may be substantially any other shape. The holesor notches 425 along an edge of the side plates 400 a,b may compriselocations at which one or more terminal brackets 200 may be attached tothe side plate. In some embodiments, the holes or notches 425 mayinterlock with corresponding notches of the terminal bracket 200 thatexist between the portions 205 and 220 (for example, at the 90 degreebend where the two portions 205 and 220 are attached). The interlockingof the side plates 400 a,b and the terminal bracket 200 may provide amechanical interlock between the side plates 400 a,b and the terminalbracket 200 that improves resistance to torque when a cable is bolted tothe terminal bracket 200. Additionally, notches 426 may compriselocations at which wires or conductors may be fed along the side plates400 a,b. In some embodiments, the notches 426 may provide cutouts forcables or cable ties (or other corresponding components) to liesubstantially flush with the side plate while holding the wire harnessesin place. In some embodiment, the hole 225 may be used to insert aterminal node or bar for coupling to other cell modules 100, etc. Insome embodiments, the dimples 230 may ensure that the terminal bracket200 contacts a face of the cell 105 just prior to an interior face (forexample, face of the terminal bracket facing the side plate) of theterminal bracket 200 contacting one of the side plates 400 a,b. Suchdimples 230 may alleviate variations in one of the side plates 400 a,bthicknesses that may cause inconsistent laser welds.

FIGS. 5A-5C illustrate an isometric view (FIG. 5A), a top view (FIG.5B), and a front view (FIG. 5C), respectively, of a wire way or wirerouting device 500, in accordance with an embodiment. In someembodiments, the wire routing device 500 may be formed from anon-conductive, semi-rigid (flexible) material. For example, the wirerouting device 500 may be formed from plastic, resin, or fiberglass. Insome embodiments, the wire routing device 500 includes a portion 501that extends substantially vertically from a base of the wire routingdevice 500. In some embodiments, the base of the wire routing device 500includes locking tabs 510 a and 510 b positioned along support arms 505and locking support 515.

The wire routing device 500 may be configured such that the base isdesigned to engage with the combination of holes 415 of the side plates400 a,b. For example, the locking support 515 may be configured to passthrough one of the holes of the combination of holes 415 of the sideplates 400 a,b and rotated to “lock” the locking support 515 one a firstside of one of the side plates 400 a,b. When rotated to lock to one ofthe side plates 400 a,b, the locking support 515 may include tabs orportions 516 a,b that, when rotated, prevent the locking support 515from passing through the respective hole of the combination of holes415. The routing device 500 may include two support arms 505 that extendhorizontally from the portion 501. The support arms 505 may include thelocking tabs 510 a and 510 b on opposite ends of the support arms 505.In some embodiments, the locking tabs 510 a and 510 b may be configuredto “lock” the wire routing device 500 in place when rotated to “lock”the locking support 515 on the first side of one of the side plates 400a,b. When in the “locked” position, the locking support 515 may be onthe first side of one of the side plates 400 a,b while the support arms505 and the remainder of the portion 501 is on a second side of one ofthe side plates 400 a,b. Thus, the locking tabs 510 a and 510 b may beconfigured to prevent the wire routing device 500 from accidentallyrotating and coming loose from the side plates 400 a,b. The portion 501may include a fork or other similarly-shaped elongated members, with aslot 525 between the fork or members. The slot 525 may be configured tohold a wire or conductor in a relative position along one of the sideplates 400 a,b. Thus, when a series of the wire routing device 500 arepositioned in a line along one of the side plates 400 a,b using thecombination of hole 415, the wire routing devices 500 may provide a pathfor wires or conductors within the open cell module 100. The interior ofthe portion 501 forming the slot 525 may be smooth to allow easymovement of the wires or conductors within the slot 525. The top of theslot 525 may include two tabbed portions 530 a and 530 b that preventwires or conductors from slipping out of the slot 525 but allow ease ofinsertion of wires or conductors into the slot 525. For example, thetabbed portions 530 a and 530 b may include a slanted or curved regionthat leads into the slot 525. The tabbed portions 530 a and 530 b mayeach include a portion that extends from an interior surface of the slot525 to reduce a gap of the slot 525 to prevent wires or conductors fromslipping out of the slot 525 vertically. Additionally, the wire routingdevice 500 may include a tabbed portion 520. In some embodiments, therecess in the tabbed portion 520 may reduce the volume of the wirerouting device 500 and maintain more consistent material thickness ofplastic in the injection molded part. In some embodiments, the tabbedportion 520 may provide a finger hold (for example, for a user orinstaller) to apply torque to the wire routing device 500 duringinstallation in the side plates 400 a,b. In some embodiments, the tabbedportion 520 may provide a structural support used to keep the wirerouting device 500 “upright” in position once locked into place.

FIG. 6 illustrates an isometric view of the wire routing device 500 ofFIG. 5 incorporated into the side plates 400 a,b of FIG. 4 of the opencell module 100 of FIG. 1, in accordance with an embodiment.

Other Considerations

It should be understood that any reference to an element herein using adesignation such as “first,” “second,” and so forth does not generallylimit the quantity or order of those elements. Rather, thesedesignations can be used herein as a convenient wireless device ofdistinguishing between two or more elements or instances of an element.Thus, a reference to first and second elements does not mean that onlytwo elements can be employed there or that the first element can precedethe second element in some manner. Also, unless stated otherwise a setof elements can include one or more elements.

Unless otherwise explicitly stated, articles such as “a” or “an” shouldgenerally be interpreted to include one or more described items.Accordingly, phrases such as “a device configured to” are intended toinclude one or more recited devices. Such one or more recited devicescan also be collectively configured to carry out the stated recitations.For example, “a processor configured to carry out recitations A, B andC” can include a first processor configured to carry out recitation Aworking in conjunction with a second processor configured to carry outrecitations B and C.

A person/one having ordinary skill in the art would understand thatinformation and signals can be represented using any of a variety ofdifferent technologies and techniques. For example, data, instructions,commands, information, signals, bits, symbols, and chips that can bereferenced throughout the above description can be represented byvoltages, currents, electromagnetic waves, magnetic fields or particles,optical fields or particles, or any combination thereof.

Various modifications to the implementations described in thisdisclosure can be readily apparent to those skilled in the art, and thegeneric principles defined herein can be applied to otherimplementations without departing from the spirit or scope of thisdisclosure. Thus, the disclosure is not intended to be limited to theimplementations shown herein, but is to be accorded the widest scopeconsistent with the claims, the principles and the novel featuresdisclosed herein. The word “exemplary” is used exclusively herein tomean “serving as an example, instance, or illustration.” Anyimplementation described herein as “exemplary” is not necessarily to beconstrued as preferred or advantageous over other implementations.

Certain features that are described in this specification in the contextof separate implementations also can be implemented in combination in asingle implementation. Conversely, various features that are describedin the context of a single implementation also can be implemented inmultiple implementations separately or in any suitable sub-combination.Moreover, although features can be described above as acting in certaincombinations and even initially claimed as such, one or more featuresfrom a claimed combination can in some cases be excised from thecombination, and the claimed combination can be directed to asub-combination or variation of a sub-combination.

In one or more aspects, the functions described may be implemented inhardware, software, firmware, or any combination thereof. If implementedin software, the functions may be stored on or transmitted over as oneor more instructions or code on a computer-readable medium.Computer-readable media includes both computer storage media andcommunication media including any medium that facilitates transfer of acomputer program from one place to another. A storage media may be anyavailable media that can be accessed by a computer. By way of example,and not limitation, such computer-readable media can comprise RAM, ROM,EEPROM, CD-ROM or other optical disk storage, magnetic disk storage orother magnetic storage devices, or any other medium that can be used tocarry or store desired program code in the form of instructions or datastructures and that can be accessed by a computer. Also, any connectionis properly termed a computer-readable medium. For example, if thesoftware is transmitted from a website, server, or other remote sourceusing a coaxial cable, fiber optic cable, twisted pair, digitalsubscriber line (DSL), or wireless technologies such as infrared, radio,and microwave, then the coaxial cable, fiber optic cable, twisted pair,DSL, or wireless technologies such as infrared, radio, and microwave areincluded in the definition of medium. Disk and disc, as used herein,includes compact disc (CD), laser disc, optical disc, digital versatiledisc (DVD), floppy disk and Blu-ray disc where disks usually reproducedata magnetically, while discs reproduce data optically with lasers.Thus, in some aspects computer readable medium may comprisenon-transitory computer readable medium (e.g., tangible media). Inaddition, in some aspects computer readable medium may comprisetransitory computer readable medium (e.g., a signal). Combinations ofthe above should also be included within the scope of computer-readablemedia.

The methods disclosed herein comprise one or more steps or actions forachieving the described method. The method steps and/or actions may beinterchanged with one another without departing from the scope of theclaims. In other words, unless a specific order of steps or actions isspecified, the order and/or use of specific steps and/or actions may bemodified without departing from the scope of the claims.

Further, it should be appreciated that modules and/or other appropriatemeans for performing the methods and techniques described herein can bedownloaded and/or otherwise obtained by a user terminal and/or basestation as applicable. For example, such a device can be coupled to aserver to facilitate the transfer of means for performing the methodsdescribed herein. Alternatively, various methods described herein can beprovided via storage means (e.g., RAM, ROM, a physical storage mediumsuch as a compact disc (CD) or floppy disk, etc.), such that a userterminal and/or base station can obtain the various methods uponcoupling or providing the storage means to the device. Moreover, anyother suitable technique for providing the methods and techniquesdescribed herein to a device can be utilized.

While the foregoing is directed to aspects of the present disclosure,other and further aspects of the disclosure may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

The scope of the present disclosure is not intended to be limited by thespecific disclosures of preferred embodiments in this section orelsewhere in this specification, and may be defined by claims aspresented in this section or elsewhere in this specification or aspresented in the future. The language of the claims is to be interpretedbroadly based on the language employed in the claims and not limited tothe examples described in the present specification or during theprosecution of the application, which examples are to be construed asnon-exclusive.

The various operations of methods described above may be performed byany suitable means capable of performing the operations, such as varioushardware and/or software component(s), circuits, and/or module(s).Generally, any operations illustrated in the Figures may be performed bycorresponding functional means capable of performing the operations.

The various illustrative logical blocks, modules, circuits, and methodsteps described in connection with the embodiments disclosed herein maybe implemented as electronic hardware, computer software, orcombinations of both. To clearly illustrate this interchangeability ofhardware and software, various illustrative components, blocks, modules,circuits, and steps have been described above generally in terms oftheir functionality. Whether such functionality is implemented ashardware or software depends upon the particular application and designconstraints imposed on the overall system. The described functionalitymay be implemented in varying ways for each particular application, butsuch embodiment decisions should not be interpreted as causing adeparture from the scope of the embodiments.

For purposes of summarizing the disclosure, certain aspects, advantagesand novel features have been described herein. It is to be understoodthat not necessarily all such advantages may be achieved in accordancewith any particular embodiment. Thus, the invention may be embodied orcarried out in a manner that achieves or optimizes one advantage orgroup of advantages as taught herein without necessarily achieving otheradvantages as may be taught or suggested herein.

Various modifications of the above-described embodiments will be readilyapparent, and the generic principles defined herein may be applied toother embodiments without departing from the spirit or scope of theapplication. Thus, the present application is not intended to be limitedto the embodiments shown herein but is to be accorded the widest scopeconsistent with the principles and novel features disclosed herein.

What is claimed is:
 1. An energy storage module, comprising: a pluralityof energy-storage cells; a set of parallel walls configured to mount theplurality of energy-storage cells between the parallel walls and havinga plurality of through-holes; a bus bar arrangement configured toelectrically couple each of the plurality of energy-storage cells to afirst terminal and a second terminal; and a wire routing deviceconfigured to mate with a plurality of the through-holes and configuredto receive one or more wires that electrically connect components of theenergy storage module.
 2. The module of claim 1, wherein the bus bararrangement comprises a first plurality of bus bars that each couples toat least two energy-storage cells of the plurality of energy-storagecells and a second plurality of bus bars that each couples to at leastone energy-storage cell of the plurality of energy-storage cells andcomprises the first or second terminal.
 3. The module of claim 2,wherein each of the first and second pluralities of bus bars comprises adepressed portion that extends from a first surface of the bus bar intoone through-hole of the plurality of through-holes.
 4. The module ofclaim 3, wherein the depressed portion comprises: a plurality ofprotrusions configured to: hold the bus bar within the one through-hole,and allow for transverse movement of the depressed portion within theone through-hole; and an opening that couples to one of theenergy-storage cells.
 5. The module of claim 3, wherein each of thesecond plurality of bus bars comprises a terminal portion that extendsaway from the first surface and includes a hole that extends through theterminal portion, wherein the hole provides for coupling to a terminalnode or another module.
 6. The module of claim 3, wherein each of thefirst plurality of bus bars comprises a plurality of depressed portionsand wherein a first of the plurality of depressed portions comprises adifferent number of protrusions than a second of the plurality ofdepressed portions.
 7. The module of claim 3, wherein each of the firstplurality of bus bars comprises an indicator that providesidentification of an orientation or alignment of the bus bar.
 8. Themodule of claim 3, wherein each of the first and second pluralities ofbus bars comprise a hole configured to provide one of a connection pointfor a conductor or a mounting point to couple the bus bar to the cellholder.
 9. The module of claim 3, wherein each of the first and secondpluralities of bus bars comprise a dimple that extends away from thefirst surface and is configured to provide spacing between the bus barand the cell holder to accommodate variations in bus bar or cell holderthickness and form.
 10. The module of claim 1, where the wire routingdevice comprises a support arm and a locking support, where each of thesupport arm and the locking support is configured to at least one ofextend into or extend through one of the through-holes of the pluralityof through-holes.
 11. A method for manufacturing an energy storagemodule, the method comprising: mounting a set of parallel walls onopposite ends of a plurality of energy-storage cells such that theplurality of energy-storage cells are positioned between the parallelwalls, each of the parallel walls having a plurality of through-holes;electrically coupling each of the plurality of energy-storage cells to afirst terminal and a second terminal via a bus bar arrangement; andmating a wire routing device with a plurality of the through-holes, thewire routing device configured to receive one or more wires thatelectrically connect components of the energy storage module.
 12. Themethod of claim 11, wherein the bus bar arrangement comprises a firstplurality of bus bars that are each coupled to at least twoenergy-storage cells of the plurality of energy-storage cells and asecond plurality of bus bars that are each coupled to at least oneenergy-storage cell of the plurality of energy-storage cells and wherethe second plurality of bus bars comprises the first or second terminal.13. The method of claim 12, wherein each of the first and secondpluralities of bus bars comprises a depressed portion that extends froma first surface of the bus bar into one through-hole of the plurality ofthrough-holes.
 14. The method of claim 13, further comprising holding,via a plurality of protrusions of the depressed portion, the bus barwithin the one through-hole, wherein the plurality of protrusions allowfor transverse movement of the depressed portion within the onethrough-hole and coupling the bus bar to one of the energy-storage cellsvia an opening in the bus bar.
 15. The method of claim 13, furthercomprising coupling each of the second plurality of bus bars to aterminal node or another module via a terminal portion that extends awayfrom the first surface and includes a hole that extends through theterminal portion.
 16. The method of claim 13, wherein each of the firstplurality of bus bars comprises a plurality of depressed portions andwherein a first of the plurality of depressed portions comprises adifferent number of protrusions than a second of the plurality ofdepressed portions.
 17. The method of claim 13, further comprisingidentifying an orientation or alignment of the bus bar based on anindicator of the bus bar.
 18. The method of claim 13, wherein each ofthe first and second pluralities of bus bars comprise a hole configuredto provide one of a connection point for a conductor or a mounting pointto couple the bus bar to the cell holder.
 19. The method of claim 13,wherein each of the first and second pluralities of bus bars comprise adimple that extends away from the first surface and is configured toprovide spacing between the bus bar and the cell holder to accommodatevariations in bus bar or cell holder thickness and form.
 20. The methodof claim 11, further comprising routing a conductor through the wirerouting device, wherein the wire routing device comprises a support armand a locking support and wherein each of the support arm and thelocking support is configured to at least one of extend into or extendthrough one of the through-holes of the plurality of through-holes.